Thermal Wall Anchor

ABSTRACT

A wall anchor for use in a cavity wall includes an elongate body having a driven end portion and a driving end portion. The driven end portion is adapted to be threadedly mounted on the inner wythe of the cavity wall. The elongate body includes a barrel portion adjacent the driven end portion. A first end of the barrel portion is adapted to abut the inner wythe of the cavity wall when installed. A thermal coating is disposed on the first end of the barrel portion. The thermal coating is configured and arranged to reduce thermal transfer in the cavity wall between the elongate body and the inner wythe when installed.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.14/313,689, filed Jun. 24, 2014, the entirety of which is incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention generally relates to anchoring systems forinsulated cavity walls, and more specifically, a thermal wall anchorthat creates a thermal break in a cavity wall.

BACKGROUND

Anchoring systems for cavity walls are used to secure veneer facings toa building and overcome seismic and other forces (e.g., wind shear,etc.). Anchoring systems generally form a conductive bridge or thermalpathway between the cavity and the interior of the building throughmetal-to-metal contact. Optimizing the thermal characteristics of cavitywall construction is important to ensure minimized heat transfer throughthe walls, both for comfort and for energy efficiency of heating and airconditioning. When the exterior is cold relative to the interior of aheated structure, heat from the interior should be prevented frompassing through to the outside. Similarly, when the exterior is hotrelative to the interior of an air conditioned structure, heat from theexterior should be prevented from passing through to the interior. Themain cause of thermal transfer is the use of anchoring systems madelargely of metal components (e.g., steel, wire formatives, metal platecomponents, etc.) that are thermally conductive. While providing therequired high-strength within the cavity wall system, the use of metalcomponents results in heat transfer. Failure to isolate the metalcomponents of the anchoring system and break the thermal transferresults in heating and cooling losses and in potentially damagingcondensation buildup within the cavity wall structure. However, acompletely thermally-nonconductive anchoring system is not ideal becauseof the relative structural weakness of nonconductive materials.

SUMMARY

In one aspect, a wall anchor for use in a cavity wall to connect to aveneer tie to join an inner wythe and an outer wythe of the cavity wallincludes an elongate body. The elongate body has a driven end portionand a driving end portion. The driven end portion is adapted to bethreadedly mounted on the inner wythe of the cavity wall. The elongatebody includes a barrel portion adjacent the driven end portion. A firstend of the barrel portion is adapted to abut the inner wythe of thecavity wall when installed. A thermal coating is disposed on the drivenend portion and the first end of the barrel portion. The thermal coatingis configured and arranged to reduce thermal transfer in the cavity wallbetween the elongate body and the inner wythe when installed.

In another aspect, a wall anchor for use in a cavity wall to connect toa veneer tie to join an inner wythe and an outer wythe of the cavitywall includes an elongate body. The elongate body has a driven endportion and a driving end portion. The driven end portion is adapted tobe threadedly mounted on the inner wythe of the cavity wall. Theelongate body includes a barrel portion adjacent the driven end portion.A first end of the barrel portion is adapted to abut the inner wythe ofthe cavity wall when installed. A thermal coating is disposed on thefirst end of the barrel portion. The thermal coating is configured andarranged to reduce thermal transfer in the cavity wall between theelongate body and the inner wythe when installed.

Other objects and features will be in part apparent and in part pointedout hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of an anchoring system as applied to a cavitywall with an inner wythe of an insulated dry wall construction and anouter wythe of brick;

FIG. 2 is a fragmentary schematic elevation, partially in section,illustrating the anchoring system in use;

FIG. 3 is a perspective of a thermal wall anchor according to anembodiment of the present invention;

FIG. 4 is a front view thereof;

FIG. 5 is a left side view of the thermal wall anchor, the right sideview being identical thereto;

FIG. 6 is a top view of the thermal wall anchor;

FIG. 7 is a bottom view thereof;

FIG. 8 is a section taken through line 8-8 of FIG. 5, illustrating thethermal coating of the wall anchor and the underlying metal components;

FIG. 9 is a perspective of a thermal wall anchor according to anotherembodiment of the present invention;

FIG. 10 is a front view thereof;

FIG. 11 is a left side view of the thermal wall anchor, the right sideview being identical thereto;

FIG. 12 is a top view of the thermal wall anchor;

FIG. 13 is a bottom view thereof;

FIG. 14 is a section taken through line 14-14 of FIG. 11, illustratingthe thermal coating of the wall anchor and the underlying metalcomponents;

FIG. 15 is a perspective of a thermal wall anchor according to stillanother embodiment of the present invention;

FIG. 16 is a front view thereof;

FIG. 17 is a left side view of the thermal wall anchor, the right sideview being identical thereto;

FIG. 18 is a top view of the thermal wall anchor;

FIG. 19 is a bottom view thereof;

FIG. 20 is a section taken through line 20-20 of FIG. 17, illustratingthe thermal coating of the wall anchor and the underlying metalcomponents;

FIG. 21 is a front view of another embodiment of a thermal wall anchor;and

FIG. 22 is a front view of another embodiment of a thermal wall anchor.

Corresponding reference characters indicate corresponding partsthroughout the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1 and 2, an anchoring system for cavity walls isshown generally at 10. A cavity wall structure generally indicated at 12comprises an inner wythe or drywall backup 14 with sheetrock orwallboard 16 mounted on metal columns or studs 17 and an outer wythe orfacing wall 18 of brick 20 construction. Between the inner wythe 14 andthe outer wythe 18, a cavity 22 is formed. An air/vapor barrier 25 andinsulation 26 are attached to an exterior surface of the inner wythe 14.

Successive bed joints 30 and 32 are substantially planar andhorizontally disposed and, in accordance with building standards, areapproximately 0.375 inches in height in a typical embodiment. Selectiveones of bed joints 30 and 32, which are formed between courses of bricks20, are constructed to receive the insertion portion of a veneer tie 44.It is understood that the described and illustrated wall structure 12 isexemplary only. Other structures may be used without departing from thescope of the present invention. A wall anchor 40 is threadedly mountedon the inner wythe 14 and is supported by the inner wythe. As describedin greater detail below, the wall anchor 40 is configured to provide athermal break in the cavity 22. The anchoring system 10 is constructedand configured to minimize air and moisture penetration around the wallanchor system/inner wythe juncture and limit thermal transfer.

For purposes of the description, an exterior cavity surface 24 of theinner wythe 14 contains a horizontal line or x-axis 34 and anintersecting vertical line or y-axis 36. A horizontal line or z-axis 38,normal to the xy-plane, passes through the coordinate origin formed bythe intersecting x- and y-axes.

In the illustrated embodiment, the anchoring system 10 includes wallanchor 40, veneer tie 44, and an optional wire or outer wythereinforcement 46. At intervals along the exterior surface 24 of theinner wythe 14, wall anchors 40 are driven into place inanchor-receiving channels 48 (see FIG. 2). Anchor-receiving channels 48can be pre-drilled, or, alternatively, wall anchor 40 can be used todrill its own channel. The wall anchors 40 are positioned so that alongitudinal axis 50 of wall anchor 40 is normal to the xy-plane andtaps into stud 17. Veneer tie 44 is shown in FIG. 1 as being placed on acourse of bricks in preparation for being embedded in the mortar of bedjoint 30. The veneer tie 44 is formed of wire and includes a U-shapedrear leg portion 42, as is known in the art. The wire reinforcement 46is also constructed of a wire, as is known in the art, and preferablyconforms to the joint reinforcement requirements of ASTM StandardSpecification A951-00, Table 1. Wall anchors and veneer ties can beconfigured in other ways within the scope of the present invention.

In a first embodiment, illustrated in FIGS. 3-8, the wall anchor 40includes an elongate body that extends along the longitudinal axis 50 ofthe anchor from a driven end portion 52 to a driving end portion 54. Thedriven end portion 52 includes a threaded portion 56 (e.g., aself-drilling screw portion). The threaded portion 56 can be configuredfor attachment to a metal stud (FIGS. 3-14), a wooden stud (FIGS.15-20), a concrete backup wall (FIGS. 15-20), or alternative backup wallconstructions. In use, the driven end portion 52 is driven into stud 17,mounting the wall anchor 40 on the inner wythe 14. The elongate body ofthe wall anchor 40 also includes a non-threaded barrel. In theembodiment of FIGS. 3-8, the wall anchor 40 includes a dual-diameterbarrel with a smaller diameter barrel or first shaft portion 58 towardthe driven end portion 52 and a larger diameter barrel or second shaftportion 60 toward the driving end portion 54.

A drive head 62 is located at the driving end portion 54 of the anchor40. The elongate body includes a flange 64 at the junction of the drivehead 62 and the barrel portion 60. The drive head 62 defines a receptoror aperture 68 for receiving the U-shaped rear leg portion 42 of theveneer tie 44. As shown in FIGS. 1 and 2, the rear leg 42 of the veneertie 44 is inserted into the aperture 68 of the drive head 62, therebysecuring the veneer tie to the wall anchor 40.

The wall anchor 40 includes a thermal coating 86 (FIG. 8) that isconfigured to provide a thermal break in the cavity 22. The maincomponents of the wall anchor are preferably made of metal (e.g., steel)to provide a high-strength anchoring system. Through the use of athermal coating, the underlying metal components of the anchor obtain alower thermal conductive value (K-value), thereby providing a highstrength anchor with the benefits of thermal isolation. Likewise, theentire cavity wall 12 obtains a lower transmission value (U-value),thereby providing an anchoring system with the benefits of thermalisolation. The term K-value is used to describe the measure of heatconductivity of a particular material, i.e., the measure of the amountof heat, in BTUs per hour, that will be transmitted through one squarefoot of material that is one inch thick to cause a temperature change ofone degree Fahrenheit from one side of the material to the other(BTU/(hr·ft·° F.); or W/(m·K) in SI units). The lower the K-value, thebetter the performance of the material as an insulator. The metalcomponents of the anchoring systems generally have a K-value range of 16to 116 W/(m·K) (about 9 to 67 BTU/(hr·ft·° F.)). The coated wall anchoras described below greatly reduces the K-values to a low thermalconductive K-value not to exceed 1 W/(m·K) (about 0.58 BTU/(hr·ft·°F.)), for example about 0.7 W/(m·K) (about 0.4 BTU/(hr·ft·° F.)). Theterm U-value is used to describe the transmission of heat through theentire cavity wall (including the anchor, the insulation, and othercomponents), i.e., the measure of the rate of transfer of heat throughone square meter of a structure divided by the difference in temperatureacross the structure. Similar to the K-value, the lower the U-value, thebetter the thermal integrity of the cavity wall, and the higher theU-value, the worse the thermal performance of the building envelope. TheU-value is calculated from the reciprocal of the combined thermalresistances of the materials in the cavity wall, taking into account theeffect of thermal bridges, air gaps and fixings. Several factors affectthe U-value, such as the size of the cavity, the thickness of theinsulation, the materials used, etc. Desirably, the use of anchor asdescribed herein may reduce the U-value of a wall by 5% -80%.

An interior surface of the aperture 68 of the drive head 62 (i.e., theportion of the wall anchor 40 that contacts the veneer tie 44) is coatedwith a thermal coating to provide a thermal break in the cavity. Otherportions of the wall anchor 40 can also include a thermal coating. Inone embodiment, the portion of the wall anchor 40 that is positioned ata juncture of the wall anchor and the inner wythe or metal stud (e.g.,the threaded portion 56 and/or the smaller barrel portion 58) includes athermal coating to reduce thermal transmission from contact of theanchor with the inner wythe and particularly the metal stud 17. In theillustrated embodiment, the drive head 42, flange 64, larger barrelportion 60, and smaller barrel portion 58 include a thermal coating. Asillustrated, portions of the anchor 40 can be uncoated (e.g., thethreaded portion 56). Alternatively, the entire wall anchor 40 can becoated. The thermal coating is selected from thermoplastics, thermosets,natural fibers, rubbers, resins, asphalts, ethylene propylene dienemonomers, and admixtures thereof and can be applied in layers. Thethermal coating optionally contains an isotropic polymer which includes,but is not limited to, acrylics, nylons, epoxies, silicones, polyesters,polyvinyl chlorides, polyethylenes, and chlorosulfonated polyethylenes.Alternatively, the thermal coating can be a ceramic or ceramic-basedcoating including materials selected from lanthanum, cerium,praseodymium, neodymium, promethium, samarium, europium, gadolinium,terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium,indium, scandium, yttrium, zirconium, hafnium, titanium, silica,zirconia, magnesium zirconate, yttria-stabilized zirconia, andderivatives and admixtures thereof. An initial layer of the thermalcoating can be cured to provide a pre-coat and the layers of the thermalcoating can be cross-linked to provide high-strength adhesion to theanchor to resist chipping or wearing of the thermal coating.

The thermal coating reduces the K-value of the underlying metalcomponents which include, but are not limited to, mill galvanized, hotgalvanized, and stainless steel. Such components have K-values thatrange from 16 to 116 W/(m·K). The thermal coating reduces the K-value ofthe anchor to not exceed 1.0 W/(m·K). Likewise, the thermal anchorreduces the U-value of the cavity wall structure. Preferably, theU-value of the cavity wall structure including the thermal anchor isreduced by 5-80% as compared to the U-value of the cavity wall structureincluding an anchor without the thermal coating described herein. Thethermal coating is fire resistant and gives off no toxic smoke in theevent of a fire. Furthermore, the coating is suited to the applicationin an anchoring system with characteristics such as shock resistance,non-frangibility, low thermal conductivity and transmissivity, and anon-porous resilient finish. Additionally, the thermal coating canprovide corrosion protection which protects against deterioration of theanchoring system over time.

The thermal coating can be applied through any number of methodsincluding fluidized bed production, thermal spraying, hot dipprocessing, heat-assisted fluid coating, or extrusion, and includes bothpowder and fluid coating to form a reasonably uniform coating. Thecoating preferably has a thickness selected to provide a thermal breakin the cavity. In one embodiment, the thickness of the coating is atleast about 3 microns, such as a thickness in the range of approximately3 microns to approximately 300 microns, and in one embodiment is about127 microns. The thermal coating is cured to achieve good cross-linkingof the layers. Appropriate examples of the nature of the coating andapplication process are set forth in U.S. Pat. No. 6,284,311 and6,612,343.

In one exemplary test, a model cavity wall structure was configured tomeasure the reduction in U-value between a non-coated anchor and ananchor having a thermal coating as described. The model comprised manylayers creating an 8 foot tall wall cross section. The wall included,from the exterior face to the interior face, an outer wythe comprisingstandard 3⅝ inch by 3⅝ inch medium density brick with a ⅜ inch mortarjoint, a 2 inch slightly ventilated air cavity, 2 inches of extrudedpolystyrene, ⅝ inch gypsum board, a 6 inch steel stud, and 1/2 inchgypsum board. Exterior and interior boundary conditions were applied tothe model. The exterior boundary condition was a −0.4° F. airtemperature and the interior boundary condition was a 69.8° F. airtemperature. In the model, veneer ties are embedded into the brickmortar and wall anchors penetrated through the extruded polystyrene andinto the steel stud. In one model, the wall anchors did not include athermal coating, and the modeled vertical cross section U-value was0.235 BTU/(hr·ft2·° F.). In another model, the wall anchors included athermal coating as described above, and the modeled vertical crosssection U-value was reduced to 0.150 BTU/(hr·ft²·° F.), nearly a 40%reduction. Although only an illustrative model, the test resultsindicate that the U-value of the cavity wall structure is greatlyreduced through use of a wall anchor with thermal coating.

As illustrated, a wall anchor 40 according to the present invention canalso include a dual seal system to prevent air and moisture penetrationthrough the cavity wall structure. An internal seal 80 is located at thejunction of the smaller and larger barrel portions 58, 60. The internalseal 80 can be a stabilizing neoprene fitting, a steel washer with aneoprene gasket, or a bonded sealing washer, such as a sealing washerhaving a backing (e.g., nylon, stainless steel, galvanized steel) with abonded sealant (e.g., ethylene propylene diene (EPDM) rubber, neoprene,silicone). When fully driven into stud 17, the threaded portion 56 andsmaller barrel portion 58 of wall anchor 40 pierce the sheetrock orwallboard 16 and air/vapor barrier 25, extending through an innerportion of anchor-receiving channel 48. As described above, theseportions of the wall anchor 40 that contact the inner wythe can includea thermal coating to prevent thermal transmission between the innerwythe and the wall anchor. The internal seal 80 covers the insertionpoint of the smaller barrel portion 58 and the threaded portion 56through the inner channel portion, precluding air and moisturepenetration through the channel and maintaining the integrity of theair/vapor barrier 25 and also providing a barrier to heat transfer.

The wall anchor 40 can also include an external seal 82 located at thejunction of the drive head 62 and the larger barrel portion 60. Theexternal seal 82 can be a stabilizing neoprene fitting, a steel washerwith a neoprene gasket, or a bonded sealing washer, such as a sealingwasher having a backing (e.g., nylon, stainless steel, galvanized steel)with a bonded sealant (e.g., EPDM rubber, neoprene, silicone). Uponinstallation of wall anchor 40 through rigid insulation 26, the largerbarrel portion 60 is forced into a press fit relationship with anexternal portion of anchor-receiving channel 48. Stabilization of thisstud-type wall anchor 40 is attained by larger barrel portion andinternal seal 80 completely filling the external channel portion, withexternal seal 82 capping the opening of the channel 48 into the cavity22 and clamping wall anchor 40 in place. The external seal 82 clamps thewall anchor 40 in place and also holds the insulation 26 in place. Thisarrangement does not leave any end play or wiggle room for pin-pointloading of the wall anchor and therefore does not loosen over time. Withexternal seal 82 in place, the insulation integrity within the cavitywall is maintained, because the larger surface area of the external sealhelps to hold the insulation in place without tearing. The external seal82 preferably extends beyond the flange 64 of the anchor 40 tocompletely seal the opening in the insulation 26. It will be understoodthat the seal system may be omitted or have a different configurationthan described within the scope of the present invention.

In producing wall anchor 40, the length of the smaller diameter barrel58 less the height of the internal seal 80 is dimensioned to match thecombined thickness of the air/vapor barrier 25 and the wall board 16.Similarly, the length of the larger diameter barrel 60 plus the heightof the internal seal 80 is dimensioned to match the thickness of theinsulation 26. This configuration allows for sealing of theanchor-receiving channels 48 upon insertion of the wall anchor 40.However, other configurations of the anchor 40 do not depart from thescope of the present invention.

A second embodiment of a wall anchor with thermal coating is illustratedin FIGS. 9-14. Wall anchor 140 is substantially similar to wall anchor40 described above, with differences as pointed out herein.

Wall anchor 140 includes an elongate body that extends along thelongitudinal axis 150 of the anchor from a driven end portion 152 to adriving end portion 154. The driven end portion 152 includes a threadedportion 156 configured for attachment to a metal stud. Wall anchor 140is used as described above with reference to wall anchor 40. Wall anchor140 includes a single diameter barrel 160. A drive head 162 is locatedat the driving end portion 154 of the anchor 140. The elongate bodyincludes a flange 164 at the junction of the drive head 162 and thebarrel 160. The drive head 162 defines a receptor or aperture 168 forreceiving a portion of a veneer tie, as described above.

The wall anchor 140 includes a thermal coating 186 (FIG. 14) that isconfigured to provide a thermal break in the cavity. The main componentsof the wall anchor are preferably made of metal (e.g., steel) to providea high-strength anchoring system. Through the use of a thermal coating,the underlying metal components of the anchor obtain a lower thermalconductive value (K-value), thereby providing a high strength anchorwith the benefits of thermal isolation. Likewise, the entire cavity wallstructure obtains a lower transmission value (U-value), therebyproviding an anchoring system with the benefits of thermal isolation. Aninterior surface of the aperture 168 of the drive head 162 (i.e., theportion of the wall anchor 140 that contacts a veneer tie) is coatedwith a thermal coating to provide a thermal break in the cavity. Otherportions of the wall anchor 140 can also include a thermal coating. Inone embodiment, the portion of the wall anchor 140 that is positioned ata juncture of the wall anchor and the inner wythe or metal stud (e.g.,the threaded portion 156 and/or the barrel portion 160) includes athermal coating to reduce thermal transmission from contact of theanchor with the inner wythe and particularly the metal stud 17. In theillustrated embodiment, the drive head 142, flange 164, and barrelportion 160 include a thermal coating. As illustrated, portions of theanchor 140 can be uncoated (e.g., the threaded portion 156).Alternatively, the entire wall anchor 140 can be coated. The thermalcoating is selected from thermoplastics, thermosets, natural fibers,rubbers, resins, asphalts, ethylene propylene diene monomers, andadmixtures thereof and can be applied in layers. The thermal coatingoptionally contains an isotropic polymer which includes, but is notlimited to, acrylics, nylons, epoxies, silicones, polyesters, polyvinylchlorides, polyethylenes, and chlorosulfonated polyethylenes.Alternatively, the thermal coating can be a ceramic or ceramic-basedcoating including materials selected from lanthanum, cerium,praseodymium, neodymium, promethium, samarium, europium, gadolinium,terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium,indium, scandium, yttrium, zirconium, hathium, titanium, silica,zirconia, magnesium zirconate, yttria-stabilized zirconia, andderivatives and admixtures thereof. An initial layer of the thermalcoating can be cured to provide a pre-coat and the layers of the thermalcoating can be cross-linked to provide high-strength adhesion to theanchor to resist chipping or wearing of the thermal coating.

The thermal coating reduces the K-value of the underlying metalcomponents which include, but are not limited to, mill galvanized, hotgalvanized, and stainless steel. Such components have K-values thatrange from 16 to 116 W/(m·K). The thermal coating reduces the K-value ofthe anchor to not exceed 1.0 W/(m·K). Likewise, the thermal anchorreduces the U-value of the cavity wall structure. Preferably, theU-value of the cavity wall structure including the thermal anchor isreduced by 5-80% as compared to the U-value of the cavity wall structureincluding an anchor without the thermal coating described herein. Thethermal coating is fire resistant and gives off no toxic smoke in theevent of a fire. Furthermore, the coating is suited to the applicationin an anchoring system with characteristics such as shock resistance,non-frangibility, low thermal conductivity and transmissivity, and anon-porous resilient finish. Additionally, the thermal coating canprovide corrosion protection which protects against deterioration of theanchoring system over time.

The thermal coating can be applied through any number of methodsincluding fluidized bed production, thermal spraying, hot dipprocessing, heat-assisted fluid coating, or extrusion, and includes bothpowder and fluid coating to form a reasonably uniform coating. Thecoating preferably has a thickness selected to provide a thermal breakin the cavity. In one embodiment, the thickness of the coating is atleast about 3 microns, such as a thickness in the range of approximately3 microns to approximately 300 microns. In one embodiment, a coatinghaving a thickness of at least about 127 microns is applied to anchor140. The thermal coating is cured to achieve good cross-linking of thelayers. Appropriate examples of the nature of the coating andapplication process are set forth in U.S. Pat. No. 6,284,311 and6,612,343.

Wall anchor 140 can also include a seal 182, which functions as seal 82described above, to preclude air and moisture penetration and maintainthe integrity of the insulation upon installation of the anchor. It willbe understood that the seal system may be omitted or have a differentconfiguration than described within the scope of the present invention.

A third embodiment of a wall anchor with thermal coating is illustratedin FIGS. 15-20. Wall anchor 240 is substantially similar to wall anchors40, 140 described above, with differences as pointed out herein.

Wall anchor 240 includes an elongate body that extends along thelongitudinal axis 250 of the anchor from a driven end portion 252 to adriving end portion 254. The driven end portion 252 includes a threadedportion 256 configured for attachment to a masonry backup wall or a woodstud. Wall anchor 240 is used as described above with reference to wallanchor 40. Wall anchor 240 includes a single diameter barrel 260. Adrive head 262 is located at the driving end portion 254 of the anchor240. The elongate body includes a flange 264 at the junction of thedrive head 262 and the barrel 260. The drive head 262 defines a receptoror aperture 268 for receiving a portion of a veneer tie, as describedabove.

The wall anchor 240 includes a thermal coating 286 (FIG. 20) that isconfigured to provide a thermal break in the cavity. The main componentsof the wall anchor are preferably made of metal (e.g., steel) to providea high-strength anchoring system. Through the use of a thermal coating,the underlying metal components of the anchor obtain a lower thermalconductive value (K-value), thereby providing a high strength anchorwith the benefits of thermal isolation. Likewise, the entire cavity wallstructure obtains a lower transmission value (U-value), therebyproviding an anchoring system with the benefits of thermal isolation. Aninterior surface of the drive head 262 defining the aperture 268 (i.e.,the portion of the wall anchor 240 that contacts a veneer tie) is coatedwith a thermal coating to provide a thermal break in the cavity. Otherportions of the wall anchor 240 can also include a thermal coating. Inone embodiment, the portion of the wall anchor 240 that is positioned ata juncture of the wall anchor and the inner wythe (e.g., the threadedportion 256 and/or the barrel portion 260) includes a thermal coating toreduce thermal transmission from contact of the anchor with the innerwythe. In the illustrated embodiment, the drive head 242, flange 264,and barrel 260 include a thermal coating. As illustrated, portions ofthe anchor 240 can be uncoated (e.g., the threaded portion 256).Alternatively, the entire wall anchor 240 can be coated. The thermalcoating is selected from thermoplastics, thermosets, natural fibers,rubbers, resins, asphalts, ethylene propylene diene monomers, andadmixtures thereof and can be applied in layers. The thermal coatingoptionally contains an isotropic polymer which includes, but is notlimited to, acrylics, nylons, epoxies, silicones, polyesters, polyvinylchlorides, polyethylenes, and chlorosulfonated polyethylenes.Alternatively, the thermal coating can be a ceramic or ceramic-basedcoating including materials selected from lanthanum, cerium,praseodymium, neodymium, promethium, samarium, europium, gadolinium,terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium,indium, scandium, yttrium, zirconium, hafnium, titanium, silica,zirconia, magnesium zirconate, yttria-stabilized zirconia, andderivatives and admixtures thereof. An initial layer of the thermalcoating can be cured to provide a pre-coat and the layers of the thermalcoating can be cross-linked to provide high-strength adhesion to theanchor to resist chipping or wearing of the thermal coating.

The thermal coating reduces the K-value of the underlying metalcomponents which include, but are not limited to, mill galvanized, hotgalvanized, and stainless steel. Such components have K-values thatrange from 16 to 116 W/(m·K). The thermal coating reduces the K-value ofthe anchor to not exceed 1.0 W/(m·K). Likewise, the thermal anchorreduces the U-value of the cavity wall structure, such as a reduction by5-80%. It is understood that other factors affect the U-value, such asthe size of the cavity, the thickness of the insulation, the materialsused, etc. The thermal coating is fire resistant and gives off no toxicsmoke in the event of a fire. Furthermore, the coating is suited to theapplication in an anchoring system with characteristics such as shockresistance, non-frangibility, low thermal conductivity andtransmissivity, and a non-porous resilient finish. Additionally, thethermal coating can provide corrosion protection which protects againstdeterioration of the anchoring system over time.

The thermal coating can be applied through any number of methodsincluding fluidized bed production, thermal spraying, hot dipprocessing, heat-assisted fluid coating, or extrusion, and includes bothpowder and fluid coating to form a reasonably uniform coating. Thecoating preferably has a thickness selected to provide a thermal breakin the cavity. In one embodiment, the thickness of the coating is atleast about 3 microns, such as a thickness in the range of approximately3 microns to approximately 300 microns. In one embodiment, a coatinghaving a thickness of at least about 127 microns is applied to anchor240. The thermal coating is cured to achieve good cross-linking of thelayers. Appropriate examples of the nature of the coating andapplication process are set forth in U.S. Pat. No. 6,284,311 and6,612,343.

Wall anchor 240 can also include a seal 282, which functions as seal 82described above, to preclude air and moisture penetration and maintainthe integrity of the insulation upon installation of the anchor. It willbe understood that the seal system may be omitted or have a differentconfiguration than described within the scope of the present invention.

Another embodiment of a wall anchor with thermal coating is illustratedin FIG. 21. Wall anchor 340 is similar to the wall anchors describedabove, with differences as pointed out herein.

Wall anchor 340 includes an elongate body that extends along thelongitudinal axis 350 of the anchor from a driven end portion 352 to adriving end portion 354. The driven end portion 352 includes a screw orthreaded portion 356 configured for attachment to a metal stud. Thescrew portion 356 can be stainless steel or other suitable metal, or canbe a polymer coated metal screw. The screw portion 356 can include athermal coating to reduce the thermal conductivity of the anchoringsystem. Wall anchor 340 includes a barrel 360 including a threadedbarrel portion 392 and a non-threaded barrel portion 394 extending fromthe threaded portion to the screw portion 356. A drive head 362 (e.g., ahex head) is located at the driving end portion 354 of the anchor 340.Wall anchor 340 is used as described above with reference to wall anchor40, but with a wing nut 390 as illustrated in phantom. The wing nut 390is disposed on the elongate body adjacent the drive head 362. The wingnut 390 defines at least one receptor or aperture 368 for receiving aportion of a veneer tie, such as pintles of a veneer tie.

The wall anchor 340 includes a thermal coating 386 that is configured toprovide a thermal break in the cavity. The main components of the wallanchor are preferably made of metal (e.g., steel) to provide ahigh-strength anchoring system. Through the use of a thermal coating,the underlying metal components of the anchor obtain a lower thermalconductive value (K-value), thereby providing a high strength anchorwith the benefits of thermal isolation. Likewise, the entire cavity wallstructure obtains a lower transmission value (U-value), therebyproviding an anchoring system with the benefits of thermal isolation.All or a portion of the anchor 340 can include a thermal coating. In theillustrated embodiment, the anchor 340 includes a thermal coating 386over the drive head 362 and part of the threaded barrel portion 392(e.g., over at least ¾ inches of threads). Optionally, the anchor 340can also include a thermal coating over the screw portion 356. Inaddition, the wing nut 390 can include a thermal coating, such as overthe entire wing nut or at least on an interior surface of the wing nutdefining the aperture 368 (i.e., the portion of the wall anchor 340 thatcontacts a veneer tie). As illustrated, portions of the anchor 340 canbe uncoated. Alternatively, the entire wall anchor 340 can be coated. Inone embodiment, the portion of the anchor 340 that is positioned at thejuncture of the wall anchor and the stud and contacts the stud wheninstalled includes a thermal coating to reduce thermal transmission fromthe metal stud. The thermal coating is selected from thermoplastics,thermosets, natural fibers, rubbers, resins, asphalts, ethylenepropylene diene monomers, and admixtures thereof and can be applied inlayers. The thermal coating optionally contains an isotropic polymerwhich includes, but is not limited to, acrylics, nylons, epoxies,silicones, polyesters, polyvinyl chlorides, polyethylenes, andchlorosulfonated polyethylenes. Alternatively, the thermal coating canbe a ceramic or ceramic-based coating including materials selected fromlanthanum, cerium, praseodymium, neodymium, promethium, samarium,europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium,ytterbium, lutetium, indium, scandium, yttrium, zirconium, hafnium,titanium, silica, zirconia, magnesium zirconate, yttria-stabilizedzirconia, and derivatives and admixtures thereof. An initial layer ofthe thermal coating can be cured to provide a pre-coat and the layers ofthe thermal coating can be cross-linked to provide high-strengthadhesion to the anchor to resist chipping or wearing of the thermalcoating.

The thermal coating reduces the K-value of the underlying metalcomponents which include, but are not limited to, mill galvanized, hotgalvanized, and stainless steel. Such components have K-values thatrange from 16 to 116 W/(m·K). The thermal coating reduces the K-value ofthe anchor to not exceed 1.0 W/(m·K). Likewise, the thermal anchorreduces the U-value of the cavity wall structure, such as a reduction by5-80%. It is understood that other factors affect the U-value, such asthe size of the cavity, the thickness of the insulation, the materialsused, etc. The thermal coating is fire resistant and gives off no toxicsmoke in the event of a fire. Furthermore, the coating is suited to theapplication in an anchoring system with characteristics such as shockresistance, non-frangibility, low thermal conductivity andtransmissivity, and a non-porous resilient finish. Additionally, thethermal coating can provide corrosion protection which protects againstdeterioration of the anchoring system over time.

The thermal coating can be applied through any number of methodsincluding fluidized bed production, thermal spraying, hot dipprocessing, heat-assisted fluid coating, or extrusion, and includes bothpowder and fluid coating to form a reasonably uniform coating. Thecoating preferably has a thickness selected to provide a thermal breakin the cavity. In one embodiment, the thickness of the coating is atleast about 3 microns, such as a thickness in the range of approximately3 microns to approximately 300 microns. In one embodiment, a coatinghaving a thickness of at least about 127 microns is applied to anchor340. The thermal coating is cured to achieve good cross-linking of thelayers. Appropriate examples of the nature of the coating andapplication process are set forth in U.S. Pat. No. 6,284,311 and6,612,343.

Wall anchor 340 can also include seals as described above, to precludeair and moisture penetration and maintain the integrity of theinsulation upon installation of the anchor. It will be understood thatthe seal system may be omitted or have a different configuration thandescribed within the scope of the present invention.

Another embodiment of a wall anchor with thermal coating is illustratedin FIG. 22. Wall anchor 440 is similar to the wall anchors describedabove, with differences as pointed out herein.

Wall anchor 440 includes an elongate body that extends along thelongitudinal axis 450 of the anchor from a driven end portion 452 to adriving end portion 454. The driven end portion 452 includes a screw orthreaded portion 456 configured for attachment to a metal stud. Thescrew portion 456 can be stainless steel or other suitable metal, or canbe a polymer coated metal screw. The screw portion 456 can include athermal coating to reduce the thermal conductivity of the anchoringsystem. Wall anchor 440 includes a barrel 460 including a threadedbarrel portion 492 and a non-threaded barrel portion 494 a non-threadedbarrel portion 494 extending from the threaded portion to the screwportion 456. A drive head 462 (e.g., a hex head) is located at thedriving end portion 454 of the anchor 440. Wall anchor 440 is used asdescribed above with reference to wall anchor 40, but with a wing nut490 as illustrated in phantom. The wing nut 490 is disposed on theelongate body adjacent the drive head 462. The wing nut 490 defines atleast one receptor or aperture 468 for receiving a portion of a veneertie, such as pintles of a veneer tie.

The wall anchor 440 includes a thermal coating 486 that is configured toprovide a thermal break in the cavity. The main components of the wallanchor are preferably made of metal (e.g., steel) to provide ahigh-strength anchoring system. Through the use of a thermal coating,the underlying metal components of the anchor obtain a lower thermalconductive value (K-value), thereby providing a high strength anchorwith the benefits of thermal isolation. Likewise, the entire cavity wallstructure obtains a lower transmission value (U-value), therebyproviding an anchoring system with the benefits of thermal isolation.All or a portion of the anchor 440 can include a thermal coating. In theillustrated embodiment, the anchor 440 includes a thermal coating 486over the drive head 462, the threaded barrel portion 492, and thenon-threaded barrel portion 494. Optionally, the anchor 440 can alsoinclude a thermal coating over the screw portion 456. In addition, thewing nut 490 can include a thermal coating, such as over the entire wingnut or at least on an interior surface of the wing nut defining theaperture 468 (i.e., the portion of the wall anchor 440 that contacts aveneer tie. As illustrated, portions of the anchor 440 can be uncoated.Alternatively, the entire wall anchor 440 can be coated. In oneembodiment, the portion of the anchor 440 that is positioned at thejuncture of the wall anchor and the stud and contacts the stud wheninstalled includes a thermal coating to reduce thermal transmission fromthe metal stud. The thermal coating is selected from thermoplastics,thermosets, natural fibers, rubbers, resins, asphalts, ethylenepropylene diene monomers, and admixtures thereof and can be applied inlayers. The thermal coating optionally contains an isotropic polymerwhich includes, but is not limited to, acrylics, nylons, epoxies,silicones, polyesters, polyvinyl chlorides, polyethylenes, andchlorosulfonated polyethylenes. Alternatively, the thermal coating canbe a ceramic or ceramic-based coating including materials selected fromlanthanum, cerium, praseodymium, neodymium, promethium, samarium,europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium,ytterbium, lutetium, indium, scandium, yttrium, zirconium, hafnium,titanium, silica, zirconia, magnesium zirconate, yttria-stabilizedzirconia, and derivatives and admixtures thereof. An initial layer ofthe thermal coating can be cured to provide a pre-coat and the layers ofthe thermal coating can be cross-linked to provide high-strengthadhesion to the anchor to resist chipping or wearing of the thermalcoating.

The thermal coating reduces the K-value of the underlying metalcomponents which include, but are not limited to, mill galvanized, hotgalvanized, and stainless steel. Such components have K-values thatrange from 16 to 116 W/(m·K). The thermal coating reduces the K-value ofthe anchor to not exceed 1.0 W/(m·K). Likewise, the thermal anchorreduces the U-value of the cavity wall structure, such as a reduction by5-80%. It is understood that other factors affect the U-value, such asthe size of the cavity, the thickness of the insulation, the materialsused, etc. The thermal coating is fire resistant and gives off no toxicsmoke in the event of a fire. Furthermore, the coating is suited to theapplication in an anchoring system with characteristics such as shockresistance, non-frangibility, low thermal conductivity andtransmissivity, and a non-porous resilient finish. Additionally, thethermal coating can provide corrosion protection which protects againstdeterioration of the anchoring system over time.

The thermal coating can be applied through any number of methodsincluding fluidized bed production, thermal spraying, hot dipprocessing, heat-assisted fluid coating, or extrusion, and includes bothpowder and fluid coating to form a reasonably uniform coating. Thecoating preferably has a thickness selected to provide a thermal breakin the cavity. In one embodiment, the thickness of the coating is atleast about 3 microns, such as a thickness in the range of approximately3 microns to approximately 300 microns. In one embodiment, a coatinghaving a thickness of at least about 127 microns is applied to anchor440. The thermal coating is cured to achieve good cross-linking of thelayers. Appropriate examples of the nature of the coating andapplication process are set forth in U.S. Pat. No. 6,284,311 and6,612,343.

Wall anchor 440 can also include seals as described above, to precludeair and moisture penetration and maintain the integrity of theinsulation upon installation of the anchor. It will be understood thatthe seal system may be omitted or have a different configuration thandescribed within the scope of the present invention.

The anchors as described above serve to thermally isolate the componentsof the anchoring system, thereby reducing the thermal transmission andconductivity values of the anchoring system as a whole. The anchorsprovide an insulating effect and an in-cavity thermal break, severingthe thermal pathways created from metal-to-metal contact of anchoringsystem components. Through the use of the thermally-isolating anchors,the underlying metal components obtain a lower thermal conductive value(K-value), thereby reducing the thermal transmission value (U-value) ofthe entire cavity wall structure. The present invention maintains thestrength of the metal and further provides the benefits of a thermalbreak in the cavity.

Having described the invention in detail, it will be apparent thatmodifications and variations are possible without departing from thescope of the invention defined in the appended claims.

When introducing elements of the present invention or the preferredembodiments(s) thereof, the articles “a”, “an”, “the” and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements.

In view of the above, it will be seen that the several objects of theinvention are achieved and other advantageous results attained.

As various changes could be made in the above products without departingfrom the scope of the invention, it is intended that all mattercontained in the above description and shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

What is claimed is:
 1. A wall anchor for use in a cavity wall to connectto a veneer tie to join an inner wythe and an outer wythe of the cavitywall, the wall anchor comprising: an elongate body having a driven endportion and a driving end portion, the driven end portion being adaptedto be threadedly mounted on the inner wythe of the cavity wall, theelongate body including a barrel portion adjacent the driven endportion, a first end of the barrel portion being adapted to abut theinner wythe of the cavity wall when installed; and a thermal coatingdisposed on the driven end portion and the first end of the barrelportion, the thermal coating being configured and arranged to reducethermal transfer in the cavity wall between the elongate body and theinner wythe when installed.
 2. The wall anchor of claim 1, wherein thefirst end of the barrel portion comprises an end surface of the barrelportion, the thermal coating being disposed on the end surface such thatthe thermal coating is positioned between the end surface and the innerwythe of the cavity when installed.
 3. The wall anchor of claim 1,wherein the driven end portion comprises a threaded portion, the thermalcoating being disposed on the threaded portion.
 4. The wall anchor ofclaim 1, wherein the thermal coating is disposed on the entire elongatebody.
 5. The wall anchor of claim 1, wherein the driving end portionincludes a drive head having an interior surface defining a receptor forreceiving a portion of a veneer tie, the thermal coating being disposedon the interior surface of the receptor such that the thermal coatingextends into the receptor to coat the interior surface defining thereceptor.
 6. The wall anchor of claim 1, wherein the barrel portion is afirst barrel portion, the elongate body further comprising a secondbarrel portion adjacent the first barrel portion and having a diameterlarger than a diameter of the first barrel portion, the thermal coatingbeing disposed on both the first and second barrel portions.
 7. The wallanchor of claim 1, wherein the driving end portion comprises a drivehead and the driven end portion comprises a threaded portion.
 8. Thewall anchor of claim 7, further comprising an external seal disposed onthe elongate body at a junction of the drive head and the barrelportion, the external seal being configured to seal a channel formed byinsertion of the wall anchor into a wall, precluding water and vaporpenetration therethrough.
 9. The wall anchor of claim 7, furthercomprising an internal seal disposed on the elongate body at a junctionof the threaded portion and the barrel portion, the internal seal beingconfigured to seal a channel formed by insertion of the wall anchor intoa wall, precluding water and vapor penetration therethrough.
 10. Thewall anchor of claim 1, wherein the thermal coating is selected from thegroup consisting of thermoplastics, thermosets, natural fibers, rubber,resins, asphalts, ethylene propylene diene monomers, acrylics, nylons,epoxies, silicones, polyesters, polyvinyl chlorides, polyethylenes,chlorosulfonated polyethylenes, lanthanum, cerium, praseodymium,neodymium, promethium, samarium, europium, gadolinium, terbium,dysprosium, holmium, erbium, thulium, ytterbium, lutetium, indium,scandium, yttrium, zirconium, hafnium, titanium, silica, zirconia,magnesium zirconate, yttria-stabilized zirconia, and derivatives andadmixtures thereof.
 11. The wall anchor of claim 1, wherein the thermalcoating has a thickness of at least about 3 microns.
 12. A wall anchorfor use in a cavity wall to connect to a veneer tie to join an innerwythe and an outer wythe of the cavity wall, the wall anchor comprising:an elongate body having a driven end portion and a driving end portion,the driven end portion being adapted to be threadedly mounted on theinner wythe of the cavity wall, the elongate body including a barrelportion adjacent the driven end portion, a first end of the barrelportion being adapted to abut the inner wythe of the cavity wall wheninstalled; and a thermal coating disposed on the first end of the barrelportion, the thermal coating being configured and arranged to reducethermal transfer in the cavity wall between the elongate body and theinner wythe when installed.
 13. The wall anchor of claim 12, wherein thefirst end of the barrel portion comprises an end surface, the thermalcoating being disposed on the end surface such that the thermal coatingis positioned between the end surface and the inner wythe of the cavitywhen installed.
 14. The wall anchor of claim 12, wherein the driven endportion comprises a threaded portion, the threaded portion being freefrom thermal coating.
 15. The wall anchor of claim 12, wherein thethermal coating is disposed on the entire elongate body.
 16. The wallanchor of claim 12, wherein the driving end portion includes a drivehead having an interior surface defining a receptor for receiving aportion of a veneer tie, the thermal coating being disposed on theinterior surface of the receptor such that the thermal coating extendsinto the receptor to coat the interior surface defining the receptor.17. The wall anchor of claim 12, wherein the barrel portion is a firstbarrel portion, the elongate body further comprising a second barrelportion adjacent the first barrel portion and having a diameter largerthan a diameter of the first barrel portion, the thermal coating beingdisposed on both the first and second barrel portions.
 18. The wallanchor of claim 12, wherein the driving end portion comprises a drivehead and the driven end portion comprises a threaded portion, the wallanchor further comprising: an external seal disposed on the elongatebody at a junction of the drive head and the barrel portion, theexternal seal being configured to seal a channel formed by insertion ofthe wall anchor into a wall, precluding water and vapor penetrationtherethrough; and an internal seal disposed on the elongate body at ajunction of the threaded portion and the barrel portion, the internalseal being configured to seal a channel formed by insertion of the wallanchor into a wall, precluding water and vapor penetration therethrough.19. The wall anchor of claim 12, wherein the thermal coating is selectedfrom the group consisting of thermoplastics, thermosets, natural fibers,rubber, resins, asphalts, ethylene propylene diene monomers, acrylics,nylons, epoxies, silicones, polyesters, polyvinyl chlorides,polyethylenes, chlorosulfonated polyethylenes, lanthanum, cerium,praseodymium, neodymium, promethium, samarium, europium, gadolinium,terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium,indium, scandium, yttrium, zirconium, hafnium, titanium, silica,zirconia, magnesium zirconate, yttria-stabilized zirconia, andderivatives and admixtures thereof.
 20. The wall anchor of claim 12,wherein the thermal coating has a thickness of at least about 3 microns.